High Pressure Pump

High Pressure Pump


• Letting the high pressure pump run dry will destroy it.

• The high pressure pump must be filled with fuel before starting the engine for the first time. Refer to => [ Fuel System, Filling/Bleeding ] Fuel System, Filling/Bleeding. (Never let the high pressure pump run dry).

• Always protect any opened fuel connections to prevent dirt from getting into them.

Special tools, testers and auxiliary items required

• Camshaft Gear Counter-Holder (T10051)

• Puller (T40064)

• Pressure Pad (T40064/1)

• Torque Wrench (5-50 Nm) (V.A.G 1331)

• Pliers (3314)

Removing

- Pay attention to the rules of cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.

- Remove the toothed belt from the camshaft and from the high pressure pump. Refer to => [ Toothed Belt ] Toothed Belt.

- Disconnect the fuel supply line - arrow - from the high pressure pump.






- Disconnect the connector - 1 - and remove the bolts - arrows -.







Be careful not to damage the wire connection when removing the connectors. Otherwise the entire wiring harness has to be replaced. Do not squeeze the pliers (3314) too hard when removing the connectors otherwise the protective sleeve will get damaged.

- Install the pliers (3314) with the groove - arrow A - on the collar of the protective sleeve - arrow B - and pull the connector off the glow plugs.






- Carefully disconnect the connectors from the glow plugs in the - direction of the arrow -.






- Remove the coolant line bolts on the intake manifold and move the coolant line to the side.

- Remove the fuel return line from the high pressure pump.

- Remove the fuel return line from the fuel rail and move it to the side.

- Remove the high pressure line between the high pressure pump and the fuel rail.

- Remove the toothed belt gear from the high pressure pump.

- Counter hold the high pressure pump hub using the camshaft gear counter-holder (T10051) and remove the nut - 1 -.






- Install the puller (T40064) with the thrust piece (T40064/1) and the pin (T40064/2) as illustrated and remove the hub from the high pressure pump. Counter hold using a 24 mm open end wrench, if necessary.






- Remove the high pressure pump bolts - arrows -.






- Remove the high pressure pump.

Installing

Install in the reverse order of removal.

For the fuel system component tightening specifications, refer to => [ Fuel System Component Overview ] Fuel System Component Overview.

Tightening specification for the toothed belt components, refer to => [ Toothed Belt Overview ] Toothed Belt Overview.